Metal-containing transaction card and method of making the same

ABSTRACT

A method of creating a single transaction card is disclosed and comprises embossing the single transaction card within a pocket to form embossed characters on a first surface of the single transaction card, filling the pocket with a fill panel to provide a substantially flush surface on a second surface of the single transaction card, wherein a third surface of the fill panel is in uniform, direct contact with an interior of the pocket. Another method is disclosed for machining a face pocket within a single transaction card and disposing a microchip therein. In various embodiments, a single transaction card is comprised of a continuous metal layer, such as, for example, titanium.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/538,745, filed Aug. 10, 2009 and entitled “METAL-CONTAININGTRANSACTION CARD AND METHOD OF MAKING THE SAME.” The '745 application isa continuation-in-part of U.S. Pat. No. 7,823,777 issued on Nov. 12,2010 (aka U.S. Ser. No. 12/125,750 entitled “Metal-ContainingTransaction Card and Method of Making the Same” filed May 22, 2008). The'777 patent is a continuation-in-part of U.S. Pat. No. 7,88,184 issuedon Sep. 15, 2009 (aka U.S. Ser. No. 11/044,662 entitled“Metal-Containing Transaction Card and Method of Making the Same” filedJan. 27, 2005). The '187 patent is a continuation-in-part of U.S. Pat.No. 7,530,491 issued May 12, 2009 (aka U.S. Ser. No. 10/749,006 entitled“Metal-Containing Transaction Card and Method of Making the Same” filedDec. 30, 2003). The '491 patent claims priority to U.S. ProvisionalPatent Application Ser. No. 60/437,938, filed Jan. 3, 2003. All of theabove-referenced applications are hereby incorporated by referenceherein in their entirety.

FIELD OF INVENTION

The invention generally includes metal-containing transaction cardsuseful for the purchase of goods and/or services and methods of makingthe same. The cards may include other features such as a microchip(e.g., smart card) disposed in a face pocket of a transaction card, anantenna and a backplate or fill panel.

BACKGROUND OF THE INVENTION

The proliferation of transaction cards, which allow the cardholder topay with credit rather than cash, started in the United States in theearly 1950s. Initial transaction cards were typically restricted toselect restaurants and hotels and were often limited to an exclusiveclass of individuals. Since the introduction of plastic credit cards,the use of transaction cards have rapidly proliferated from the UnitedStates, to Europe, and then to the rest of the world. Transaction cardsare not only information carriers, but also typically allow a consumerto pay for goods and services without the need to constantly possesscash, or if a consumer needs cash, transaction cards allow access tofunds through an automatic teller machine (ATM). Transaction cards alsoreduce the exposure to the risk of cash loss through theft and reducethe need for currency exchanges when traveling to various foreigncountries. Due to the advantages of transaction cards, hundreds ofmillions of cards are now produced and issued annually, therebyresulting in a need for companies to differentiate their cards fromcompetitor's cards.

Initially, the transaction cards often included the issuer's name, thecardholder's name, the card number, and the expiration date embossedonto the card. The cards also usually included a signature field on theback of the card for the cardholder to provide a signature to protectagainst forgery and tampering. Thus, the cards served as devices toprovide data to merchants and the security associated with the card wasthe comparison of the cardholder's signature on the card to thecardholder's signature on a receipt along with the embossed cardholder'sname on the card.

Due to the popularity of transaction cards, numerous companies, banks,airlines, trade groups, sporting teams, clubs and other organizationshave developed their own transaction cards. As such, many companiescontinually attempt to differentiate their transaction cards andincrease market share not only by offering more attractive financingrates and low initiation fees, but also by offering unique,aesthetically pleasing features on the transaction cards. As such, manytransaction cards include not only demographic and account information,but the transaction cards also include graphic images, designs,photographs and security features. A recent security feature is theincorporation of a diffraction grating, or holographic image, into thetransaction card which appears to be three-dimensional. Holographicimages restrict the ability to fraudulently copy or reproducetransaction cards because of the need for extremely complex systems andapparatus for producing holograms.

Administrative and security issues, such as charges, credits, merchantsettlement, fraud, reimbursements, etc., have increased due to theincreasing use of transaction cards. Thus, the transaction card industrystarted to develop more sophisticated transaction cards which allowedthe electronic reading, transmission, and authorization of transactioncard data for a variety of industries. For example, magnetic stripecards, optical cards, smart cards, calling cards, and supersmart cardshave been developed to meet the market demand for expanded features,functionality, and security. In addition to the visual data, theincorporation of a magnetic stripe on the back of a transaction cardallows digitized data to be stored in machine readable form. As such,magnetic stripe readers are used in conjunction with magnetic stripecards to communicate purchase data received from a cash register deviceon-line to a host computer along with the transmission of data stored inthe magnetic stripe, such as account information and expiration date.

Due to the susceptibility of the magnetic stripe to tampering, the lackof confidentiality of the information within the magnetic stripe and theproblems associated with the transmission of data to a host computer,integrated circuits were developed which may be incorporated intotransaction cards. These integrated circuit (IC) cards, known as smartcards, proved to be very reliable in a variety of industries due totheir advanced security and flexibility for future applications.However, even integrated circuit cards are susceptible tocounterfeiting.

As magnetic stripe cards and smart cards developed, the market demandedinternational standards for the cards. The card's physical dimensions,features and embossing area were standardized under the InternationalStandards Organization (“ISO”), ISO 7810 and ISO 7811. The issuer'sidentification, the location of particular compounds, codingrequirements, and recording techniques were standardized in ISO 7812 andISO 7813, while chip card standards were established in ISO 7813. Forexample, ISO 7811 defines the standards for the magnetic stripe which isa 0.5 inch stripe located either in the front or rear surface of thecard and which is divided into three longitudinally parallel tracks. Thefirst and second tracks hold read-only information with room for 79alphanumeric characters and 40 numeric characters, respectively. Thethird track is reserved for financial transactions and includesenciphered versions of the user's personal identification number,country code, currency units, amount authorized per cycle, subsidiaryaccounts, and restrictions.

More information regarding the features and specifications oftransaction cards can be found in, for example, Smart Cards by Jose LuisZoreda and Jose Manuel Oton, 1994; Smart Card Handbook by W. Rankl andW. Effing, 1997, and the various ISO standards for transaction cardsavailable from ANSI (American National Standards Institute), 11 West42nd Street, New York, N.Y. 10036.

The incorporation of machine-readable components onto transactions cardsencouraged the proliferation of devices to simplify transactions byautomatically reading from and/or writing onto transaction cards. Suchdevices include, for example, bar code scanners, magnetic stripereaders, point of sale terminals (POS), automated teller machines (ATM)and card-key devices. With respect to ATMs, the total number of ATMdevices shipped in 1999 was 179,274 (based on Nilson Reports data)including the ATMs shipped by the top ATM manufacturers, namely NCR(138-18 231st Street, Laurelton, New York 11413), Diebold (5995 Mayfair,North Canton, Ohio 44720-8077), Fujitsu (11085 N. Torrey Pines Road, LaJolla, Calif. 92037), Omron (Japan), OKI (Japan) and Triton.

Typical transaction cards are made from thermoplastic materials, such aspolyvinyl chloride (PVC) and polyethylene terephthalate (PET). However,these transaction cards are susceptible to being damaged or destroyed ifexposed to damaging environments. For example, transaction cards may bedamaged if left exposed to the elements for an extended period of time.Moisture and/or sunlight may break down the chemical bonds within thepolymers of typical transaction cards, such that transaction cards leftexposed to moisture and sunlight may become warped, cracked andunusable. In addition, thermoplastic transaction cards may be easilybent or may be broken or cut, thereby damaging the transaction card andrendering it unusable.

A need, therefore, exists for a transaction card that has both strengthand durability. Moreover, a need exists for a transaction card thatwithstands exposure to the elements, such as moisture or sunlight. Aneed further exists for a transaction card that may incorporate thefeatures noted above, such as holograms, signature panels, magneticstripes, microchips, and the like, such that is has both strength anddurability. In addition, a need exists for a transaction card thatovercomes the problems noted above.

SUMMARY OF THE INVENTION

The present invention relates to a metal-containing transaction card anda method of making the same. The transaction card may have a magneticstripe, an embedded microchip, a signature panel, a holographic image,or any other feature typically contained on or within the transactioncard. The transaction card of the present invention may have at leastone layer of metal. The transaction card of the present invention mayhave at least one layer of titanium or stainless steel.

A transaction card and a method of making the same are provided wherebythe transaction card may have at least one layer of metal. The at leastone layer of metal may provide durability and strength to thetransaction card. The one layer of metal may be any metal able to beutilized as a transaction card or incorporated into or within atransaction card. The at least one layer of metal may be titanium,stainless steel or aluminum.

Further, a transaction card having at least one layer of metal isprovided whereby the transaction card may be of a standard size, i.e.,compliant with the International Standards Organization (ISO) fortransaction cards.

In addition, a transaction card having at least one layer of metal mayfurther have other layers that include one or more polymeric materialsor other metal material, such as aluminum and the like.

Still further, a metal-containing transaction card is provided havingfeatures typically contained on or in transaction cards, such asmagnetic stripes, embedded microchips, signature panels, holographicimages, and the like. Moreover, the metal-containing transaction cardmay be printed with indicia, such as via screen-printing or alaser-etching process to uniquely identify the transaction card and/orthe issuer of the transaction card or any other information.

Additional features and advantages of the present invention aredescribed in, and will be apparent from, the detailed description of thepresently preferred embodiments and from the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a plan view of a front face of a metal-containingtransaction card;

FIG. 1B illustrates a plan view of a back face of a metal-containingtransaction card;

FIG. 2A illustrates a cross-sectional view of a metal-containingtransaction card along line II-II of FIG. 1B;

FIG. 2B illustrates a cross-sectional view of an alternate embodiment ofa transaction card along line II-II of FIG. 1B;

FIG. 2C illustrates a cross-sectional view of another alternateembodiment of a transaction card along line II-II of FIG. 1B;

FIG. 2D illustrates a cross-sectional view of a still further alternateembodiment of a transaction card along line II-II of FIG. 1B;

FIG. 2E illustrates a cross-sectional view of another alternateembodiment of a transaction card along line II-II of FIG. 1B;

FIG. 3 illustrates a flow chart showing a method of makingmetal-containing transaction cards;

FIG. 4 illustrates a flow chart showing an alternate method of makingtitanium transaction cards;

FIG. 5 illustrates another flow chart showing an alternate method oftitanium transaction cards;

FIG. 6 illustrates an alternate flow chart showing a still furtheralternate method of making titanium transaction cards;

FIG. 7 illustrates a still further alternate flow chart showing analternate method of making titanium transaction cards with embossedcharacters, a magnetic stripe and a signature panel;

FIG. 8 illustrates a plan view of a titanium card made by the methods ofmaking the titanium transaction cards;

FIG. 9 illustrates a plan view of an inset fill panel made during themethods of making the titanium transaction cards;

FIG. 10 illustrates a plan view of an embossed titanium card withadhesive disposed in the pockets;

FIG. 11 illustrates a plan view of a titanium card having a fill paneldisposed within a pocket and a magnetic stripe and signature paneldisposed in the other pockets;

FIG. 12 illustrates a cross-sectional view of the titanium card havingthe fill panel disposed within the pocket and a magnetic stripe andsignature panel disposed in other pockets;

FIGS. 13A and 13B illustrate a method of making a metal transactioncard;

FIGS. 14A-14C illustrate a metal transaction card;

FIG. 15 illustrates a method of making a metal transaction card;

FIG. 16 illustrates a method of making a metal transaction cardincluding personalization of a metal transaction card.

DETAILED DESCRIPTION

The detailed description of exemplary embodiments herein makes referenceto the accompanying drawings, which show exemplary embodiments by way ofillustration and its best mode. While these exemplary embodiments aredescribed in sufficient detail to enable those skilled in the art topractice the invention, it should be understood that other embodimentsmay be realized and that logical, procedural and mechanical changes maybe made without departing from the spirit and scope of the invention.Thus, the detailed description herein is presented for purposes ofillustration only and not of limitation. For example, the steps recitedin any of the method or process descriptions may be executed in anyorder and are not necessarily limited to the order presented. Moreover,many of the functions or steps may be outsourced to or performed by oneor more third parties. Furthermore, any reference to singular includesplural embodiments, and any reference to more than one component or stepmay include a singular embodiment or step. Also, any reference toattached, fixed, connected or the like may include permanent, removable,temporary, partial, full and/or any other possible attachment option.Additionally, any reference to without contact (or similar phrases) mayalso include reduced contact or minimal contact.

Metal-containing transaction cards and methods of making the same areprovided. The transaction cards may be standard-sized (i.e., about 3⅜inches by about 2¼ inches) or any other size yet still usable as atransaction card. Moreover, the transaction card may have a magneticstripe, an embedded microchip, a signature panel, a holographic image,or any other feature typically contained on or within a transactioncard. The transaction cards may have at least one layer of metal,including titanium or stainless steel.

Referring now to the drawings, wherein like numerals refer to likeparts, FIG. 1 illustrates a plan view of a metal-containing transactioncard 1 having a front face 10. The transaction card 1 may be composed ofat least one layer of metal that has been flattened into a card shape.Typically metal can be rolled into a sheet. The sheet can then be cut toform individual transaction cards.

Any metal may be utilized as the layer or layers of the transactioncards described herein. Specifically, the metals may include titanium,stainless steel, or aluminum, although any other metal is contemplatedby the present invention. The transaction card of the present inventionmay comprise titanium.

On the front surface 10 of the transaction card 1 may be indicia, suchas images, graphics, words, or other symbols, that may be printed on thefront surface 10 using conventional printing techniques. Alternatively,the indicia may be laser-etched. A typical laser-etching device forlaser-etching metal, such as titanium or stainless steel, is done by alaser from Virtek Vision International, Inc. Lasers can provide markingof metals such as titanium, stainless steel or aluminum of depths of upto 0.100 inches and as low as about 0.003 inches. A pattern may be lasermarked onto the front face 10 (or the rear surface 20, as describedbelow and illustrated by FIG. 1B).

In addition, the laser-etching of the metal layer, typically titanium,may provide the transaction card 1 with a plurality of colors on one orboth of the faces of the card 1. Specifically, the energy utilized tolaser-etch the metal may allow the metal to recrystallize in such a wayas to be viewable by an individual as being of a specific color orcolors.

In an alternative embodiment, one or both surfaces of the transactioncard 1 may be anodized using conventional anodizing methods, therebyproviding one or both surfaces of the transaction card 1 that may sealedwith an oxide layer thereby protecting the metal and allowing thesurface to be receptive to printing inks or coatings. In addition, theanodizing process may provide a color to one or both surfaces of thetransaction card 1. For example, the anodizing process may comprisetreatment of the surface of the metal with an ionic solution under anelectrical current, which can provide one or both faces of thetransaction card 1 with a color depending on the voltage of theelectricity that is used to anodize the one or both faces of thetransaction card 1.

A coating may be applied to one or both faces of the transaction card 1.The coating may be a silane compound thereby providing the metal in thetransaction card 1 resistance to scratches, damage, fingerprints, andthe like. In addition, a dye or ink may be incorporated into the silanecoating thereby providing the transaction card 1 with a particularcolor. Typically, the silane and the dye are provided across one or bothsurfaces of the transaction card 1. The silane coating may beincorporated with a black dye whereby one or both surface of thetransaction card 1 will have a black appearance. Of course, any othercolored coating may be applied to the surface of one or both faces ofthe transaction card 1 after one or both surfaces of the transactioncard 1 are anodized, such as acrylic or polyethylene terephthalate. Inaddition, the surface coating may be comprised of a thermoset polymericmaterial, applied to one or both surfaces of the transaction card. Thethermoset material may be applied to the transaction card 1 by coatingone or both surfaces of the transaction card 1 with dry powder of thethermoset material, and baking the thermoset material to melt the sameand set the material on the surface of the transaction card 1. Ofcourse, the transaction card 1 may be provided with no colored coating,thereby providing a metal-colored transaction card, whereby the naturalcolor of the metal may be viewable.

FIG. 1B illustrates a rear surface 20 of the transaction card 1 of thepresent invention.

Provided on the rear surface 20 may be a magnetic stripe 22 that may beapplied to the rear surface 20 using conventional methods, such as bystamping the magnetic stripe to the transaction card 1. Moreover, asignature panel 24 may be provided as well and may also be stamped tothe transaction card 1 or applied via any other conventional method. Thesignature panel allows the owner of the transaction card to place his orher signature on the transaction card, thereby providing a securityfeature. In addition, a microchip may be embedded into the transactioncard of the present invention. Of course, any other feature may beincluded on the front surface 10 or the rear surface 20 of thetransaction card 1 as may be apparent to one having ordinary skill inthe art.

FIG. 2A illustrates a cross-sectional side view of the transaction card1 along lines II-II of FIG. 1B. As illustrated, the transaction card 1includes at least a first layer 26 of metal. Of course, the transactioncard 1 may comprise two or more layers of metal that are adheredtogether via heat, pressure, and/or adhesive. The transaction card I mayinclude at least one layer of titanium or stainless steel. The firstlayer 26 further includes the magnetic stripe 22 and the signature panel24 adhered directly to the first layer 26 of metal. The total thicknessof the first layer 26 may be about 30 mils, although other thicknessesof the first layer 26 are contemplated by the present invention. Thelayers illustrated in FIGS. 2A-2E are exaggerated in thickness toclearly illustrate the structures of the transaction cards describedherein.

The transaction card 1 may be stamped, embossed or etched to providetexture, images, alphanumeric characters, or the like. As describedabove, the front or rear surfaces of the transaction card 1 may beprinted or laser-etched to provide indicia, such as graphics, images,text, or any other indicia. In addition, the surface of the first layer26 may be anodized and/or coated with a coating to protect the surfacesof the metal and/or to provide the surface with a color. Moreover, anadhesive (not shown) may be provided for adhering the magnetic stripe 22and the signature panel 24 to the metal of the first layer 26. Further,a microchip (not shown) may be embedded into the first layer 26 of metalto provide smart card capabilities to the transaction card madetherefrom.

FIG. 2B illustrates an alternate embodiment of the present invention ofa cross-sectional view of the transaction card 1 along line II-II ofFIG. 1B. As illustrated, the transaction card 1 includes a metal layer30, and an optional adhesive layer 32 to adhesively secure the magneticstrip 22 and signature panel 24 to the metal layer 30. The adhesivelayer 32 may be laminated, coated, or otherwise applied to the metallayer 30. The total thickness of the transaction card 1 including themetal layer 30 and the adhesive layer 32, as illustrated in FIG. 2B, maybe about 30 mils, although other thicknesses are contemplated in thepresent invention. The metal layer 30 may be made of titanium orstainless steel.

Alternatively, the transaction card does not include an adhesive layer,as illustrated in FIG. 2A, and the magnetic stripe 22 and/or signaturepanel 24, as well as any other feature, is applied directly to one orboth surfaces of the metal layer 30. Alternatively, the transaction card1 may have an adhesive layer (not shown) provided on the front face 10of the transaction card 1 for adhering inks or other printing to themetal layer 30.

The transaction card of FIG. 2B may be stamped, embossed or etched toprovide texture, images, graphics, alphanumeric characters or the liketo the transaction card. As described above, the front or rear surfacesof the transaction card may be printed or laser-etched to provideindicia, such as graphics, images, text, or any other indicia.

FIG. 2C illustrates an alternate embodiment of the present invention ofa cross-sectional view of a transaction card taken along line II-II ofFIG. 1B. In the embodiment illustrated in FIG. 2C, the transaction card1 comprises a core layer 40 of a substrate, such as a thermoplasticmaterial of, for example, PVC, PET copolymer, or other substrate.Further, the core layer 40 has a layer of metal laminated to one or bothsides of the core layer 40. In FIG. 2C, the core layer 40 has a firstmetal layer 42 laminated or otherwise disposed adjacent to a firstsurface of the core layer 40 and a second metal layer 44 laminated orotherwise disposed adjacent to a second surface of the core layer 40.The core layer 40 may be about 18 mils, while each metal layer 42, 44may be about 6 mils to provide a transaction card that is about 30 milsin total thickness. However, the core layer 40 and metal layers 42, 44may be any thickness. The metal layers 42, 44 may be titanium orstainless steel.

Provided on the second metal layer 44 may be an adhesive 46 laminated orotherwise applied thereto for providing adhesion for the magnetic stripe22, signature panel 24, or other feature typically included on atransaction card. Alternatively, an adhesive layer (not shown) isprovided on the first metal layer 42 for providing adhesion to inks forprinting purposes, or for any other reason. Alternatively, there is noadhesive layer between the magnetic stripe 22, signature panel 24, orother feature typically included on the transaction card and the firstand/or second metal layers 42, 44.

In addition, the transaction card of FIG. 2C may be stamped, embossed oretched to provide texture, images, graphics, alphanumeric characters orthe like to the transaction card. As described above, the front or rearsurfaces of the transaction card may be printed or laser-etched toprovide indicia, such as graphics, images, text, or any other indicia.

FIG. 2D illustrates a fourth embodiment of the present invention,whereby the transaction card 1, illustrated in a cross-sectional view inFIG. 2D, comprises a first layer 50 of a substrate, such as athermoplastic material of, for example, PVC or PET copolymer, and asecond layer 52 of metal laminated or otherwise disposed adjacent to thefirst layer 50. The first layer 50 and the second layer 52 may havethicknesses that sum to about 30 mils. For example, the first layer maybe about 18 mils and the second layer (of metal) may be about 12 mils.However, the layers may be any other thicknesses. The second layer 52 ofmetal may be titanium or stainless steel.

The first layer 50 may further include an adhesive 54 to provideadhesion to the magnetic stripe 22, the signature panel 24, or to anyother feature contained on the transaction card 1. Alternatively, noadhesive layer is present.

FIG. 2E illustrates a fifth embodiment of the present invention, wherebythe transaction card 1, illustrated in a cross-sectional view in FIG.2E, comprises a first layer 60 of a metal substrate, such as aluminum,or other metal substrate, and a second layer 62 of a second metallaminated or otherwise disposed adjacent to the first layer 60. Thesecond layer 62 may be titanium or stainless steel, although othermetals are contemplated by the present invention. As with thetransaction cards described above, the first layer 60 may have anadhesive layer 64 laminated or otherwise applied thereto for providingadhesion to the magnetic stripe 22 and/or the signature panel 24. Aswith the other embodiment described above, the adhesive may be providedon the second layer as well for providing adhesion to inks for printing,or for other features typically contained on a transaction card.Alternatively, no adhesive layer is present and the magnetic stripe 22and/or the signature panel 24 are adhered directly to the metalsubstrate 60.

The following embodiments described herein and illustrated in FIGS. 3-12relate specifically to transaction cards made from titanium. However, itshould be noted that the present invention should not be limited asdescribed, but should also include embodiments whereby other metals,blends and alloys are utilized.

FIG. 3 illustrates a method 100 of making a metal-containing transactioncard of the present invention, wherein the metal is titanium.Specifically, the method 100 includes a first step 102 of preparing thetitanium to form into transaction cards. Specifically a sheet oftitanium may be prepared that is about 30 mils thick. Typically, thetitanium metal is rolled and flattened to the required thickness. Thetitanium sheet may comprise titanium metal that has little to nomagnetic properties, so that the titanium does not interfere with themagnetic stripe and/or microchip that may be embedded within thetransaction card.

In an anodizing step 104, the titanium sheet is anodized using aconventional anodizing process. Specifically, the titanium may bedisposed in a bath having ions and an electrical current therein toanodize one or both of the faces of the sheet of titanium. As notedabove, anodizing the sheet of titanium can provide one or both faces ofthe sheet of titanium with a colored surface, depending on the currentthat is supplied during the anodizing process, as is apparent to onehaving ordinary skill in the art. Moreover, anodizing oxidizes thesurface of the titanium, thereby sealing and protecting the titanium.

In a coating step 106, a coating is applied to one or both faces of thesheet of titanium to provide one or both faces of the sheet with a colorand to further protect the titanium. Specifically, the coating may be asilane coating having a dye contained therein, wherein the silane iscoated as a layer on one or both faces of the transaction card. Thesilane coating may be applied in a waterless solvent or a water-basedsystem. In addition, other materials that may be coated to one or bothfaces of the transaction card are polyethylene terephthalate andacrylic, although any other coating may be utilized to provide a coatingto protect the titanium and, optionally, to provide a color to the oneor both faces of the transaction card. For example, the coating may bemade from a thermoset material that may be sprayed onto the one or bothsurfaces of the transaction card in powder form. The transaction cardmay then be baked, and the powder may melt to the surface of thetransaction card.

Step 108 illustrates a cutting step whereby the sheet of titanium, whichmay have been anodized and/or coated as described above, may be cut intoindividual transaction card shapes. Common methods of cutting titaniuminclude, but are not limited to, water jet cutting, die cutting, lasercutting or plasma cutting. The goal in cutting the titanium is to easilyand efficiently cut the titanium sheet into transaction card shapeswhile avoiding sharp edges.

After cutting the titanium sheet via step 108, the individualtransaction cards may be laser-engraved via a laser-engraving step 110.The laser engraving may be done via commonly known laser engravingtechniques to provide a pattern in one or both faces of the transactioncard. Moreover, the laser engraving may cut away a coating that may bedisposed on the one or both faces of the transaction card, therebyproviding a visible pattern. For example, if a black coating is appliedto the titanium sheet via step 106, the laser beam may etch a pattern inthe black coating to give a pattern that is not black, but may be metalcolored, or colored in any other way. In addition, the laser beam maymelt the surface of one or both faces of the transaction card, which maycause the titanium to recrystallize when cooled. The recrystallizationmay produce a variety of colors in the surface of one or both faces ofthe transaction card. The laser engraving step 110 may be accomplishedvia a laser, such as, for example, a YAG laser having a wavelength ofabout 1064 nanometers. Of course, any other laser may be utilized thatprovides a pattern, a texture or a color to the titanium as may beapparent to one having ordinary skill in the art.

After laser engraving the transaction card, a magnetic stripe andsignature panel of the transaction card may be applied to thetransaction card via step 112. Typically, the magnetic stripe and thesignature panel are stamped using techniques common in the art of makingtransaction cards. Specifically, the magnetic stripe and signature panelare applied to one or both of the surfaces of the transaction card withthe use of an adhesive that may be applied on one or both surfaces ofthe transaction card. The adhesive may be screen-printed to one or bothsurfaces of the transaction card, although any other method of applyingthe adhesive is contemplated by the present invention. Most materialsrequire the use of an adhesive to adhere to one or both surfaces of thetransaction card. However, certain coatings may allow the magneticstripe and the signature panel to be applied without the use ofadhesives. For example, a coating of thermoplastic, such as a flat blackvinyl thermoplastic, may be coated onto the card and may allow themagnetic stripe and the signature panel to be applied to the transactioncard without adhesive. The stamping process may melt the thermoplasticmaterial, thereby allowing the thermoplastic material to adhere themagnetic stripe and/or the signature panel when cooled and solidified.

After the magnetic stripe and the signature panel have been applied tothe transaction card, the transaction card may be milled via step 114 toprovide a space to apply an embedded microchip for a smart card. Themilling process may be done in a similar manner to conventional plastictransaction cards, but may be accomplished with a boron nitride or boroncarbide tipped machine or other machine able to mill titanium. Inaddition, the transaction card may be milled via a cryo-milling process,in which the mill head is cooled with a stream of liquid nitrogen toensure that the transaction card and/or the mill head does not overheat.Typically, the transaction card may have an area about 20 to about 25mils deep milled from the transaction card to provide a space for amicrochip. The microchip may be applied to the milled area of thetransaction card, and may stay within the milled area due to an adhesivethat may be disposed therein.

After milling the transaction card to embed the microchip therein, thetransaction card may be embossed via an embossing step 116.Specifically, the embossing may be done by subjecting the transactioncard to a high pressure die that may punch a character or a plurality ofcharacters into the surface of the transaction card. The embossing maybe done to provide information on the surface of the transaction cardthat may be readable by an individual or a machine. Specifically, anaccount number or other unique identifier is typically embossed on atransaction card. The embossing step 116 may be accomplished with anaddressograph machine. Of course, other methods of embossing thetransaction card are contemplated, and the invention should not belimited as herein described.

Finally, the transaction card may be encoded via step 118 via anyencoding steps commonly used to encode the transaction cards.Specifically, either or both of the recordable media, such as themagnetic stripe and/or the microchip, may be encoded to provide thetransaction card having information contained therein. The recordablemedia may be read via a magnetic stripe reader or a microchip reader, asmay be apparent to one having ordinary skill in the art.

FIG. 4 illustrates an alternate method 200 of making transaction cardscomprising titanium. The method 200 comprises a first step 202 ofpreparing the titanium by rolling and flattening the titanium into asheet to form into transaction cards. The first step 202 may besubstantially similar to the first step 102 described above with respectto FIGS. 3.

After the titanium sheet is prepared via step 202, the titanium sheetmay be cut in a cutting step 204, whereby the sheet of titanium may becut into individual transaction card shapes. For example, the titaniumsheet may be cut via the methods described above with respect to step108 of FIG. 3.

Once the individual transaction cards have been cut from the titaniumsheet, each individual transaction card may be tumbled and cleaned tosmooth any sharp edges via a tumbling and cleaning step 206. It isimportant to ensure that all of the edges are smooth.

After the transaction cards have been smoothed and cleaned, eachtransaction card may be anodized and primed via an anodizing step 208.The anodizing step may be substantially similar to the anodizing step104 as described above with reference to FIG. 3.

After being anodized and primed, each transaction card may be coated andoven cured via a coating step 210. The coating step 210 may besubstantially similar to the coating step 106 as described above withreference to FIG. 3. Each side of each transaction card may be coatedand oven-cured separately in a multi-step process.

After each side of each transaction card is coated and oven-cured, eachtransaction card may be laser engraved via laser engraving step 212,which may be substantially similar to the laser-engraving step 110, asdescribed above with reference to FIG. 3.

Once each transaction card is laser engraved, a primer may be applied toone or both of the surfaces by screen printing the primer via a primingstep 214. The primer may be applied across the entire surface of eachtransaction card, or may be applied precisely where the magnetic stripeand/or signature panels are desired.

After each transaction card is primed, the magnetic stripe and/orsignature panels may be applied via step 216. The magnetic stripe and/orsignature panel may be applied in a substantially similar way asdescribed in step 112, described above with respect to FIG. 3.

After the magnetic stripe and/or signature panels have been applied,each of the surfaces of each transaction card may be laser scored viastep 218 to provide graphics, text and numerals to either or both of thesurfaces of each transaction card.

Once each transaction card has been laser scored to provide graphics,text, numerals and/or other indicia, a microchip may be disposed withinthe transaction card via step 220. For example, the transaction card maybe milled to provide a space in the transaction card for an embeddedmicrochip. The disposing of the microchip into the transaction card viastep 220 may be done in a substantially similar manner as step 114,described above with reference to FIGS. 3.

Each transaction card may then be embossed via an embossing step 222,which may be substantially similar to the embossing step 118, asdescribed above with reference to FIG. 3. Finally, each transactioncard's recordable media, such as the magnetic stripe and/or the embeddedmicrochip, may be encoded via an encoding step 224.

In an alternate method 300 of making titanium transaction cardsillustrated in FIG. 5, sheets of titanium are prepared via step 302. Thetitanium sheets may be prepared as described above in steps 102, 104with respect to FIGS. 3, 4, respectively. Specifically sheets oftitanium may be prepared that are about 30 mils thick. In addition,other sheets of titanium may be prepared that are about 15 mils thick,that will be cut into inset fill panels, as described below. Typically,the titanium metal is rolled and flattened to the required thickness.The titanium sheets may comprise titanium metal that has little to nomagnetic properties, so that the titanium does not interfere with themagnetic stripe and/or a microchip that may be embedded within thetransaction card.

The 30 mil thick titanium sheets are then cut into individual cards viastep 304. At the same time, the edges of the individual cards may bebeveled to create chamfer edges. The chamfer edges may be prepared onboth surfaces of each individual card on all four edges of each titaniumcard. Alternatively, the chamfer edges may be prepared on only onesurface of each titanium card, such as on a front surface of eachtitanium card. In addition, at the same time that the chamfer edges areprepared, a pocket may be milled into each individual card. The pocketmay be milled into a backside of each transaction card at the samelocation on the transaction card where the transaction card is embossedto provide characters on the front surface of each transaction card.

Referring now to FIG. 5, the 15 mil thick titanium sheets may then becut into individual inset fill panels via step 306. The inset fill panelwill fit within the pocket when placed therein with a suitable adhesive.When the inset fill panel is disposed within the pocket with a suitableadhesive, the inset fill panel forms a smooth surface on the backside ofthe titanium card.

Both the titanium cards and the inset fill panels may then be brushedvia step 308 to provide a nice finish on each transaction card.Typically, the brushing is done via known titanium brushing techniquesto provide titanium surfaces having a grain running in the samedirection. The brushing may also create titanium surfaces on eachtransaction card having another pattern.

Both surfaces of each titanium card may be coated via step 310 byphysical vapor deposition (“PVD”) of a coating that may be utilized toboth protect the titanium surfaces and provide a distinctive appearance.The coating may be titanium carbonitride, which, when vapor deposited onthe surfaces of each titanium card, provides an even and substantiallyblack coating to each surface of each titanium card. One surface of eachfill panel may also be coated by physical vapor deposition.Specifically, the surface of the fill panel that is disposed on theoutside of the transaction card when the fill panel is adhesivelydisposed within the pocket should be coated by physical vapordeposition. Other coating techniques may also be utilized to provide thecoating on the titanium card as apparent to one having skill in the art.

Graphics may then be laser etched into the titanium card via step 312.Specifically, the laser etching may etch both the coating and thetitanium to provide the graphics, as described above.

Primer or adhesive material may be applied to the backside of eachtitanium card via step 314 to allow the magnetic stripe and/or thesignature panel to be hot stamped thereon, via step 316. A primermaterial that may be utilized is known as “passport transfer material,”and may be utilized to allow the magnetic stripe and the signature panelto adhere to the titanium and/or the coating applied by physical vapordeposition, as described above. The signature panel and/or the magneticstripe may be substantially similar to or identical to typical magneticstripes and/or signature panels typically utilized in transaction cards.

Each titanium card may then be embossed via step 318. The embossing ofthe characters may be applied on the surface of the titanium within thepocket, such as with an addressograph machine. The embossing is donewithin the pocket so that the embossing may be done in titanium that isthinner than the total thickness of the transaction card. It has beenfound that embossing the characters in thinner titanium is easier, andprovides clearer and more visible characters, without distortion orwarping of the characters or of the transaction card.

The recordable media that may be contained within each titanium card maythen be recorded via step 320. For example, magnetic stripes aretypically disposed on a surface of a transaction card. The magneticstripe disposed on the surface of each titanium card may be encoded viastep 320. In addition, if other recordable media are present, such as anembedded microchip, it may be encoded via step 320.

Each embossed character displayed on the front surface of eachtransaction card may then be “tipped” or sanded or abraded to remove thecoating applied by the physical vapor deposition via step 322. Thisallows each character to obtain a metallic hue that is easily andclearly visible when contrasted with the substantially black coating onthe remainder of the transaction card.

The inset fill panel 360 may then be adhered within the pocket 352 viastep 324. A suitable adhesive may be utilized that adheres the titaniumsurface of the inset fill panel 360 with the titanium surface within thepocket 352 or the coating that may be on the surface of within thepocket 352 by physical vapor deposition. A suitable adhesive is known as“die mount adhesive”, which is a heat activated film.

FIG. 6 illustrates an alternate method 400 of making titaniumtransaction cards. The method 400 is similar to the method 300,described above with respect to FIG. 5. However, the transaction cardmade by the method 400 may have a chamfer edge that is bare. In otherwords, the titanium transaction card may have a coating thereon, such asapplied via physical vapor deposition. However, the chamfer edges mayhave a metallic hue because the coating may be removed at the edges tocreate a transaction card having a metallic “frame” around eachtransaction card.

A first step 402 of preparing the titanium sheets may be similar, if notidentical, to the step of preparing the sheets via step 302 as describedin FIG. 5, above. Step 404 entails applying the coating to the titaniumsheets so that the entire titanium sheets are coated prior to cuttingthe sheets into individual cards and inset fill panels, which is donevia step 406. When cutting each titanium sheet into individual titaniumcards via step 406, each edge of each transaction card may be beveled tocreate the chamfer edges without the coating disposed thereon. Thepocket may also be milled during step 406.

The fill panels are cut from the 15 mil thick titanium sheets via step408. When coating the titanium sheets utilized as the fill panels, onlyone surface of the sheet need be coated via vapor deposition. However,having both surfaces coated by physical vapor deposition does not changethe method described herein.

Each chamfer edge may be brushed and cleaned via step 410 to providesmooth edges having metallic grain running in the same direction.Alternatively, the edges may be brushed to provide patterns in thetitanium on the edges of the transaction cards.

The titanium cards may then be etched to provide graphics via step 412.Primer may be applied to a surface of the titanium transaction cards forthe magnetic stripe and signature panel via step 414. The magneticstripe and signature panel may be applied via step 416. The card maybeembossed via step 418. The recordable media may be encoded via step 420.Each embossed character may be “tipped” via step 422, and the fill panelmay be adhered within the pocket via step 424. Each step 412-424 may besubstantially similar to or identical to the steps 312-324, as describedabove with respect to FIG. 5.

FIG. 7 illustrates a still further embodiment of a method of makingtitanium transaction cards 500. Specifically, the method 500 comprises afirst step 502 of machining the titanium into cards with pockets forembossing and application of a magnetic stripe and a signature panel.FIG. 8 illustrates a titanium transaction card 550 comprising anembossing pocket 552 disposed within one or more layers of titanium 554,a signature panel pocket 556 disposed within the titanium 554, and amagnetic stripe pocket 558 disposed within the titanium 554. An insetfill panel 560, as illustrated in FIG. 9, is punched pursuant to step504.

A PVD coating is applied to one or more surfaces of the titaniumtransaction card to provide a surface coating, such as a black surfacecoating, on the one or more surfaces of the titanium transaction cardsvia step 506. The transaction card 550 may have other types of coatingsto provide protection of the titanium or to otherwise protect thetitanium.

PVC, or other suitable adhesive material, is disposed within thesignature panel pocket 556 and/or the magnetic stripe panel 558 via step508. As illustrated in FIG. 10, the PVC material, or other adhesivematerial, forms an adhesive layer 566 within the signature panel pocket556 and an adhesive layer 568 within the magnetic stripe panel 558.

A signature panel and magnetic stripe are hot stamped into the signaturepanel pocket 556 and magnetic stripe pocket 358 via step 510. Thesignature panel 570 and magnetic stripe 572, as illustrated in FIG. 11,are applied over the adhesive layer 566 and adhesive layer 568, disposedwithin the signature panel pocket 556 and magnetic stripe pocket 558,respectively. The adhesive layers 566, 568 provide for adequate adhesionof the signature panel 570 and magnetic stripe 572 to the titanium. Thepockets allow the signature panel 570 and magnetic stripe 572 to remaincoplanar with the surface of the card.

Graphics are laser etched on the PVD coating of the titanium transactioncard 550 via step 512. Characters 562 are then embossed via step 514within an embossing pocket 552. The relative thinness of the titanium inthis area allows embossing to be accomplished easily. Adhesive 564 isthen applied within the embossing pocket 552, typically hot-stamped, sothat the inset fill panel 560 may be adhered within the embossing pocket552 via step 516.

The tips of the embossed characters are then abraded via step 518 toexpose the titanium. This allows the characters to take on a metallichue, which stands out against the black PVD coating of the surface ofthe titanium transaction card.

The magnetic stripe 572 is then encoded, and the transaction cardaccount number may be printed onto the signature panel 570. Finally, theedges and the characters are polished via step 522.

FIG. 12 illustrates a cross-sectional view of the titanium transactioncard 550 illustrated in FIG. 11. Specifically, the titanium transactioncard 550 includes the inset fill panel 560 disposed over the adhesive564 within the embossing pocket 552. The characters 562 are embossedthrough the embossing pocket 552 prior to adherence of the inset fillpanel 560. In addition, the signature panel 570 and magnetic stripe 572are illustrated, adhered to the titanium via adhesive layers 566, 568,respectively. As illustrated, the signature panel 570 and the magneticstripe 572 are coplanar with the surface of the card.

Although the above embodiment of the present invention, illustrated inFIGS. 8-12, shows only an embossing pocket 352, a signature pocket 356and a magnetic stripe pocket 358, any other pocket may be milled, cut orotherwise disposed in one or more surfaces of a metal-containingtransaction card to provide a location for a transaction card feature.For example, a transaction card feature may include, as noted above,signature panels, magnetic stripes, microchips, holographic images, orany other feature providing information and/or security thereon ortherewithin. The present invention should not be limited as hereindescribed with respect to FIGS. 8-12.

In various embodiments, the present invention includes a metaltransaction card that may comprise a card body and a back panel. Invarious embodiments, the present invention includes a method forfabricating a metal transaction card that may comprise a card body, amicrochip and a back panel. FIGS. 13A-13B and 14A-14C depict a method ofmaking a metal transaction card and one embodiment of such a metaltransaction card.

A card body may comprise any metal or composite. A card body may havethe standard transaction card dimensions or may include non-standarddimensions. A card body may further comprise plastic, including PVC,PVB, or polycarbonate. A card body may comprise only a single layer ofmetal or multiple layers of metal. Metal used to construct the cardbody, as used herein, may be any metal or metal alloy. For example,titanium, stainless steel, alloys thereof and combinations thereof maybe used to construct the card body. A card body may be prepared 1301,1305 by any method discussed herein. A card body may be cut, punched orshaped 1302, 1306 from a sheet of metal. Any method of cutting metaldisclosed herein may be used to cut a first portion from a sheet ofmetal. As would be appreciated by one skilled in the art, some devices(e.g., hopper) used in the card production process rely on suction tohold and move individual cards through various steps, includingembossing steps. A metal containing card body may be incompatible withconventional suction devices as a metal containing card body may not beflexible. In various embodiments, a device that may hold and move metalcontaining cards may be used.

A card body may include a pocket to receive a back panel. A card bodymay have a pocket to receive a microchip. A pocket may be milled,drilled, lasered, or otherwise created in the card body. For example,card body 1407 has pocket 1401 milled to accept back panel 1406. Alsofor example, card body 1407 has pocket 1410 milled to accept microchip1403. As a further example, card body 1407 has pocket 1402 milled toaccept a signature panel. The procedure for creating this pocket viamilling is described below with reference to the card making process1308.

A back panel may be any layer of metal. A back panel may be any layer ofplastic. The metal used to construct the back panel may be any metal ormetal alloy. For example, titanium, stainless steel, alloys thereof andcombinations thereof may be used to construct the back panel. A backpanel may be prepared 1301, 1305 by any method discussed herein. A backpanel may be cut 1303, 1307 from a sheet of metal. Any method of cuttingmetal disclosed herein may be used to cut a back panel from a sheet ofmetal. A back panel may have the standard transaction card dimensions.In one embodiment, the back panel may include one or more dimensionsthat are smaller than a card body (as further described below).

A card body may have indicia disposed on, within or above a surface.Indicia include legal notices, regulatory compliance messages, phonenumbers, URLs, email addresses, trademarks, pictures, graphics, barcodes, or any other readable or understandable symbol. Indicia may bedisposed in any manner suitable for the material of the card body. Forexample, indicia may be printed onto the card body. Printing may becompleted with any suitable type of ink that bonds to metal or plastic.Also for example, indicia may be etched onto the card body. Etching maybe accomplished by a laser. Etching may be accomplished chemically, orthrough milling, grinding, pressing, stamping, embossing or scratching.For example, indicia 1404 (also referred to as embossed characters 1404)may be pressed or embossed onto a card body 1407. Also for example,indicia 1408 may be laser etched onto card body 1407. As an additionalexample, indicia 1409 may be printed onto card body 1407. To facilitatethe pressing or embossing of indicia onto a card body, a pocket may bemilled on one surface of the card body. Milling may involve the removalof card body material over an area.

After a pocket is created, a pressing, stamping or embossing process maybe used to create indicia. The embossing of the characters may beapplied on the surface of the titanium within the pocket, such as withan addressograph machine. The pressing, stamping or embossing may becompleted within the pocket so that the embossing may be completed in aportion of the titanium or other metal that is thinner than the totalthickness of the transaction card. Pressing, stamping or embossingindicia in thinner titanium may be easier, and may provide clearer andmore visible characters on the other side of the metal surface, withoutdistortion or warping of the characters or of the card body itself. Theindicia made by pressing or embossing may be raised above the surfacethat is opposite the pocket. Pressing, stamping or embossing metal tocreate raised indicia may create indicia that are sharp or otherwiseinconvenient to use in a transaction card. As such, raised indicia maybe further milled, polished, ground, or otherwise reduced in thickness.

A back panel may have indicia disposed on a surface. Indicia includelegal notices, regulatory compliance messages, phone numbers, URLs,email addresses, trademarks, pictures, graphics, bar codes, or any otherreadable or understandable symbol. Indicia may be disposed in any mannersuitable for the material of the back panel. For example, indicia may beprinted onto the back panel. Printing may be completed with any suitabletype of ink that will bond to metal or plastic. Also for example,indicia may be etched onto the back panel. Etching may be accomplishedby a laser. Etching may be accomplished chemically. or through milling,grinding, pressing, embossing or scratching. For example, indicia 1405may be printed on back panel 1406. In many jurisdictions, transactioncards are required to display particular pieces of information. A backpanel having indicia disposed thereon is one approach to fulfillingcertain requirements for different regions. By disposing indicia on aback panel, one card body may be manufactured and then paired with anappropriate back panel. This reduces production costs while stillallowing a transaction card issuer to comply with applicableregulations.

A back panel may be bonded to a card body. Bonding 1304, 1309 may beaccomplished by coupling a back panel and a card body and subjecting thecombination to suitable temperatures and pressures. Any pressuresuitable for bonding may be used. Bonding may occur at any pressure highenough so that bonding would be effective. Bonding may occur at anypressure lower than that which would unacceptably deform either the cardbody or back panel. Any suitable temperature suitable for bonding may beused. For example, bonding may occur at about 275 degrees F. (135degrees C.). Further, bonding may occur at any temperature high enoughso that bonding would be effective. Bonding may occur at any temperaturelower than that which would melt or otherwise unacceptably deform eitherthe card body or back panel. Bonding may take place over any suitableamount of time. Bonding time may be dependent on the temperature andpressure used. For example, bonding may occur over the course of 15seconds. Bonding may be performed with no adhesive. Bonding may beperformed with an adhesive disposed between the card body and the backpanel. Many adhesives are known in the art that are suitable for such aprocess. For example, ABLEBOND 931-1T1N1 may be used.

A card body may have a microchip disposed thereon. The position of themicrochip on the card may be standardized by industry practice (forexample, ISO 7816). Many jurisdictions may now require a microchip intransaction cards. The high temperatures and pressures that may beassociated with a bonding process may damage any microchip or othersemiconductor disposed on or in a card body. To minimize this risk, theback panel may be positioned on the card body such that the hightemperatures and pressures of the binding process do not damage themicrochip. Positioning the back panel below a signature panel may avoiddamage to a microchip during the milling process. For example, a backpanel may have a size of 3.056 in by 0.829 in. A back panel may bebonded to a card body such that the distance from the bottom of the cardbody to the bottom of the back panel is 0.13 in. A back panel may bebonded to a card body such that the distance from the bottom of the cardbody to the bottom of the back panel is less than 0.13 in. A back panelmay be bonded to a card body such that the distance from the top of thecard body to the top of the back panel is 1.171 in. A back panel may bebonded to a card body such that the distance from the top of the cardbody to the top of the back panel is less than 1.171 in. A back panelmay be bonded to a card body such that the distance from each side ofthe card body to each side of the back panel is 0.159 in. A back panelmay be bonded to a card body such that the distance from each side ofthe card body to each side of the back panel is less than 0.159 in ormore than 0.159.

A microchip may be disposed onto a card body in a variety of ways. Acard body may have material removed across an area to accommodate amicrochip. For example, a pocket may be milled into the card body. Apocket may be milled so that a microchip may sit flush with the surfaceof the card body. An adhesive may be disposed in the pocket or on themicrochip prior to positioning a microchip into a pocket in a card body.Any suitable adhesive may be used. For example, ABLEBOND 931-1T1N1 maybe used for this purpose. Further, in various embodiments, an insulatingmaterial may be disposed in the card body pocket to be positionedbetween the microchip and the card body so as to electrically insulatethe microchip and the card body. An adhesive may act as an insulatingmaterial. Any insulator may be used for this purpose. Insulatingproperties may be beneficial as when the card body is made of metal,contact between the card body and some kinds of microchips may cause anelectrical failure.

With reference to FIGS. 15 and 16, a method for making a titaniumtransaction card is disclosed. Although titanium is used forillustration purposes, in various embodiments, transaction cards areconstructed of any material or combination of materials such as, forexample, stainless steel and/or aluminum, as described herein. Any ofthe steps shown in FIGS. 15 and 16 may be performed by one or moreparties and in one or more locations. With reference to FIG. 15,titanium plates 1501 and titanium strips 1502 may be comprised anymaterial comprising titanium. For example, titanium plates 1501 andtitanium strips 1502 may comprise pure titanium and/or various titaniumalloys. Titanium plates 1501 may be of any thickness described herein,for example, between 4 mils to 40 mils thick, and in various embodimentstitanium plates 1501 are 30 mils thick. Titanium plates 1501 may beprecut to the exact dimensions of a standard transaction card or theapproximate dimensions of a standard transaction card (e.g., less than3.5 inches in length and less than 2.25 inches in width), but in variousembodiments titanium plates 1501 are two or more times the size of astandard transaction card such that two or more standard transactioncards may be cut from one of titanium plates 1501. Titanium strips 1502are suitable for use as fill panels, as described in detail herein, andmay be precut to the approximate dimensions of a finished fill panel(e.g., about 3.056 in by about 0.829 in, or any dimension such that thesurface area of the fill panel is less than a standard transactioncard). In various embodiments, titanium strips 1502 are sized so thatmultiple finished fill panels may be formed from titanium strips 1502.In various embodiments, titanium strips 1502 have varying thicknesses,for example from about 1 mil to about 30 mils thick, and in variousembodiments, titanium strips 1502 are about 15 mils thick.

Titanium plates 1501 may be surface finished in surface finishing step1504. For example, a surface of a titanium plate 1501 may be ground,sanded, polished, buffed, and/or otherwise worked to produce a suitablesurface. Similar surface finishing may performed on titanium strips 1502in surface finishing step 1506. Titanium plates 1501 and titanium strips1502 may be cleaned with a solvent, surfactant, wax, and/or othercleaning agent.

Titanium plates 1501 may be cut into card bodies in cutting step 1508.Cutting may be performed using any method described herein, for exampleby the methods contemplated by step 108. For example, common methods ofcutting titanium include water jet cutting, die cutting, laser cuttingand plasma cutting. Titanium strips 1502 may be cut in cutting step 1510using any of the methods disclosed for use in step 1508.

Titanium plates 1501 may then have an embossing pocket machined into onesurface in machining step 1512. An embossing pocket as used herein mayalso be referred to as a rear pocket. Machining step 1512 may comprisemilling, drilling, mortising, shaving, routing, grinding or any othermethod by which titanium may be removed to form a pocket. In variousembodiments, the embossing pocket comprises a bottom surface and two ormore side surfaces. The embossing pocket may be of varying depth, fromabout 1 mil to about 30 mils, and in various embodiments the embossingpocket has a depth of about 15 mils. In various embodiments, theembossing pocket has the same depth as titanium strips 1502.

In various embodiments, a face pocket is machined into titanium plates1501 in machining step 1514. The machining of step 1512 may comprise anymethod disclosed with respect to step 1510. In various embodiments, theface pocket is disposed on a surface opposite the embossing pocket. Theface pocket may be of varying depth, from about 1 mil to about 20 mil.In various embodiments, machining step 1514 is used to create pocket1410, as shown in FIG. 14B.

Titanium plates 1501 and titanium strips 1502 may be coated via PVD inPVD coating step 1516, as described above. Titanium nitride and/ortitanium carbonitride may be used to coat titanium plates 1501 andtitanium strips 1502. Coating titanium plates 1501 and titanium strips1502 may provide protection to the titanium and, in various embodiments,imparts a black finish on the titanium. PVD coating step 1516 producescoated titanium card bodies 1517 and coated titanium strips 1518.

In various embodiments, coated card bodies 1517 and coated titaniumstrips 1518 may undergo separate processing. Coated card bodies 1517 mayhave magnetic stripes applied in magnetic strips application step 1522.Magnetic stripes are a form of recordable media and may be applied usingany known adhesive. Magnetic stripes may be configured to containvarious account information, including account number and account holdername.

Signature panels may be applied to coated titanium card bodies 1517 insignature panel application step 1524. Signature panels may be appliedusing an adhesive suitable for bonding to metal surfaces. Signaturepanels may comprise a writable surface such as, for example writablewith pencil or ink.

Coated titanium card bodies 1517 may be engraved in engraving step 1528.Engraving step 1528 includes engraving by conventional means, butengraving as used with reference to engraving step 1528 also includeslaser and acid etching. Any information or design may be disposed oncoated titanium card bodies 1517 in engraving step 1528. For example,account information and company branding (including logos ortrademarks/tradenames) may be engraved on coated titanium card bodies1517 in engraving step 1528

In various embodiments where coated card bodies 1517 comprise a facepocket, a microchip may be disposed in the face pocket in chip embeddingstep 1532. An adhesive may be disposed in the face pocket or on themicrochip prior to positioning the microchip into the face pocket. Invarious embodiments, the microchip is disposed in a coated card body1517 such that the microchip is substantially flush with one surface ofthe coated card body 1517. Any suitable adhesive may be used to disposethe microchip into the face pocket. For example, ABLEBOND 931-1T1N1 maybe used for this purpose. Further, in various embodiments, an insulatingmaterial may be disposed in the card body pocket to be positionedbetween the microchip and the card body so as to electrically insulatethe microchip and the card body. An adhesive may act as an insulatingmaterial. Any suitable insulator may be used for this purpose.Insulating properties may be beneficial as contact between the card bodyand some kinds of microchips may cause an electrical failure.

An adhesive tape may be disposed on coated titanium strips 1518 inadhesive application step 1534. Any suitable adhesive or adhesive tapemay be used, including any adhesive tape that is suitable for bonding tometal surfaces. In various embodiments, heat activated adhesive tapeand/or heat activated adhesive is used.

Coated titanium strips 1518 may be stamped in stamping step 1536. Forexample, coated titanium strips 1518 may be stamped using a press toprovide compression and shaping. In various embodiments, stamping mayalter the dimensions of coated titanium strips 1518.

With reference to FIG. 16, magnetic stripe encoding may be performed inmagnetic stripe encoding step 1601. As discussed above, magnetic stripemay be encoded with account information. Encoding may be performed usingany means now known or developed hereafter.

Coated titanium card bodies 1517 may be embossed in embossing step 1602.Embossing may comprise the use of a stamp under pressure and/or heat topress characters into coated titanium card body 1517. Embossing maycreate embossed characters that protrude from one surface of coatedtitanium card body 1517 and corresponding indented characters on anothersurface of coated titanium card body 1517. For example, embossing step1602 may be used to form embossed characters 1404, as shown FIG. 14B,and characters 562, as shown in FIG. 12. Any suitable stamp may be usedin embossing. For example, a stamp may comprise a metal die shaped inthe form of numeric and/or alphanumeric characters. Embossing may beperformed within the embossing pocket. Because embossing through theembossing pocket entails embossing through less titanium material incontrast to embossing through the entire thickness of coated titaniumcard bodies 1517, lower embossing pressures may be used. Embossingthrough the entire thickness of coated titanium card body 1517 entailsusing embossing pressures that may lead to unacceptable and/orirreversible deformation of coated titanium card body 1517. By embossingthrough the embossing pocket, less pressure is needed and coatedtitanium card body 1517 may remain substantially intact.

Although embossing through the embossing pocket, as described herein,may include less pressure than embossing through the entire thickness ofcoated titanium card body 1517, embossing step 1602 may cause coatedtitanium card body 1517 to deform or bow to some degree. Debowing step1603 may be used to remove bowing and/or other deformity from coatedtitanium card body 1517. Debowing 1603 may be performed using anysuitable machinery, such as a press or card flattener.

Embossed characters formed during embossing 1602 may be milled inmilling step 1604 to smooth the embossed characters. Milling maycomprise polishing, brushing, grinding, or any use of an abrasive tosmooth, grind, abrade, or finish the embossed characters. In variousembodiments, milling 1604 removes at least a portion of the coating onthe embossed characters.

The embossing pocket of coated titanium card body 1517 may be filledwith a fill panel, for example, coated titanium strip 1518, in applyinginsert step 1605 to produce an assembled card. The filling of theembossing pocket may be performed in any suitable manner. For example,hot pressing or hot stamping may be used to bond coated titanium strip1518 to the embossing pocket. Hot pressing or hot stamping may be usefulin embodiments where a heat activated adhesive tape is applied to coatedtitanium strip 1518, such as, for example, that which may be performedin step 1534. In various embodiments, after filling step 1605, the fillpanel provides a substantially flush surface on a surface of thetransaction card. For example, with reference to FIG. 12, titaniumtransaction card 550 is depicted with inset fill panel 560 disposedwithin embossing pocket 552, providing a substantially flush surface ona surface of transaction card 550. In various embodiments, once disposedin the embossing pocket, a surface of the fill panel is in uniform,direct contact with an interior surface of the pocket. It is understoodthat a surface of the fill panel and an interior surface of the pocketmay be considered to be in uniform, direct contact in embodiments wherean adhesive or adhesive tape is used to join the two surfaces and inembodiments where only heat and pressure act to join the two surfaces.

An assembled card may be polished in polishing step 1606. Polishing maybe performed in any suitable manner, for example, as described above.Polishing 1606 may be performed with various solvents, surfactants,and/or polishes, although it in various embodiments the materials usedin polishing 1606 will be minimally reactive (if at all) to bothtitanium any coating on the assembled card. In various embodiments, waxis used to polish an assembled card.

It should be noted that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications may be madewithout departing from the spirit and scope of the present invention andwithout diminishing its attendant advantages. It is, therefore, intendedthat such changes and modifications be covered by the appended claims.

Benefits, other advantages, and solutions to problems have beendescribed herein with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any elements that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as critical, required, or essentialfeatures or elements of the invention. The scope of the invention isaccordingly to be limited by nothing other than the appended claims, inwhich reference to an element in the singular is not intended to mean“one and only one” unless explicitly so stated, but rather “one ormore.” Moreover, where a phrase similar to ‘at least one of A, B, and C’is used in the claims, it is intended that the phrase be interpreted tomean that A alone may be present in an embodiment, B alone may bepresent in an embodiment, C alone may be present in an embodiment, orthat any combination of the elements A, B and C may be present in asingle embodiment; for example, A and B, A and C, B and C, or A and Band C. Although the invention has been described as a method, it iscontemplated that it may be embodied as computer program instructions ona tangible computer-readable carrier, such as a magnetic or opticalmemory or a magnetic or optical disk. All structural, chemical, andfunctional equivalents to the elements of the above-described exemplaryembodiments that are known to those of ordinary skill in the art areexpressly incorporated herein by reference and are intended to beencompassed by the present claims. Moreover, it is not necessary for adevice or method to address each and every problem sought to be solvedby the present invention, for it to be encompassed by the presentclaims. Furthermore, no element, component, or method step in thepresent disclosure is intended to be dedicated to the public regardlessof whether the element, component, or method step is explicitly recitedin the claims. No claim element herein is to be construed under theprovisions of 35 U.S.C. 112, sixth paragraph, unless the element isexpressly recited using the phrase “means for.” As used herein, theterms “comprises”, “comprising”, or any other variation thereof, areintended to cover a non-exclusive inclusion, such that a process,method, article, or apparatus that comprises a list of elements does notinclude only those elements but may include other elements not expresslylisted or inherent to such process, method, article, or apparatus.

1. A method of creating a single transaction card comprising: embossingthe single transaction card within a pocket to form embossed characterson a first surface of the single transaction card; and filling thepocket with a fill panel, wherein a second surface of the fill panel isin uniform, direct contact with an interior of the pocket.
 2. The methodof claim 1, wherein an entire surface of the single transaction card iscomprised of a continuous metal layer.
 3. The method of claim 1, furthercomprising milling the embossed characters.
 4. The method of claim 1,wherein the pocket was formed by machining.
 5. The method of claim 2,wherein the continuous metal layer comprises at least one of titanium,aluminum or stainless steel.
 6. The method of claim 2, furthercomprising coating the continuous metal layer via physical vapordeposition.
 7. The method of claim 6, wherein the physical vapordeposition deposits titanium nitride on the continuous metal layer. 8.The method of claim 1, wherein the single transaction card furthercomprises a face pocket and further comprising disposing a microchip inthe face pocket.
 9. The method of claim 1, wherein the fill panelcomprises at least one of titanium, aluminum or stainless steel.
 10. Themethod of claim 1, wherein the fill panel provides a substantially flushsurface on a second surface of the single transaction card.
 11. A methodof creating a single transaction card comprising: machining a rearpocket within the single transaction card, wherein the singletransaction card is configured to be embossed within the rear pocket toform embossed characters on a first surface of the single transactioncard, wherein the single transaction card is configured to have a fillpanel disposed within the rear pocket, wherein a second surface of thefill panel is configured to be in uniform, direct contact with aninterior of the rear pocket.
 12. The method of claim 11, furthercomprising machining a face pocket within the single transaction card,wherein the single transaction card is configured to have a microchipdisposed within the face pocket of the single transaction card.
 13. Themethod of claim 11, wherein the single transaction card is comprised ofa continuous metal layer.
 14. The method of claim 13, wherein thecontinuous metal layer comprises at least one of titanium, aluminum orstainless steel.
 15. The method of claim 13, further comprising coatingthe continuous metal layer via physical vapor deposition.
 16. The methodof claim 15, wherein the physical vapor deposition deposits titaniumnitride on the continuous metal layer.
 17. A single transaction cardcomprising: embossed characters on a first surface of the singletransaction card; a fill panel disposed in a rear pocket of the singletransaction card, wherein a second surface of the fill panel is inuniform, direct contact with an interior of the rear pocket.
 18. Thetransaction card of claim 17, further comprising a face pocket having amicrochip disposed within the face pocket.
 19. The transaction card ofclaim 17, further comprising a coating disposed on the continuous metallayer by physical vapor deposition.
 20. The transaction card of claim17, wherein said coating comprises titanium nitride.